Coupling assembly for coupling a rod to a bone anchoring element and bone anchoring device with such a coupling assembly

ABSTRACT

A coupling assembly is provided for coupling a rod to a bone anchoring element, the coupling assembly including
         a receiving part ( 5, 5′, 5 ″) with a top end ( 5   a ) and an opposite bottom end ( 5   b );   a section ( 52 ) for receiving the rod and   an accommodation space ( 55, 56 ) for accommodating a head ( 3 ) of the bone anchoring element, the accommodation space being in communication with the top end of the receiving part through a passage ( 51; 120 ) and being in communication with the bottom end through an opening ( 57 ) at the bottom end for inserting the head; and   a pressure element ( 7, 7′, 7 ″) located at least partially in the accommodation space, the pressure element having a cap portion ( 72 ) configured to encompass the head;   wherein the pressure element ( 7, 7′, 7 ″) can assume in the receiving part an inserting position in which inserting of the head into the receiving part is permitted, a locking position in which the head can be locked in the receiving part and a pre-locking position in which the pressure element is pivotable in the receiving part and wherein the pressure element is arranged such that the cap portion ( 72 ) narrows the opening ( 57 ) at the bottom end ( 5   b ) to prevent removal of the head ( 3 ),   wherein a first retaining element ( 8   a,    8   b ) is provided that prevents the pressure element from moving further towards the top end ( 5   a ) in the insertion position and   wherein a second retaining element ( 11, 60, 60 ″) different from the first retaining element is provided that prevents the pressure element from moving further towards the top end ( 5   a ) in the pre-locking position.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure claims the benefit of U.S. Provisional Patent Application Ser. No. 61/763,426, filed Feb. 11, 2013, the contents of which are hereby incorporated by reference in their entirety, and claims priority from European Patent Application EP 13154823.2, filed Feb. 11, 2013, the contents of which are hereby incorporated by reference in their entirety.

BACKGROUND

The invention relates to a coupling assembly for coupling a rod to a bone anchoring element and a bone anchoring device with such a coupling assembly. The coupling assembly includes a receiving part and a pressure element located at least partially in an accommodation space of the receiving part. The pressure element has a flexible portion to clamp a head of the bone anchoring element. It can assume in the receiving part an insertion position in which insertion and removal of the head is permitted, a locking position, in which the head is locked in the receiving part and a pre-locking position in which the head is pivotable but prevented from removal from the receiving part.

US 2010/0234902 A1 describes a receiving part for receiving a rod for coupling the rod to a bone anchoring element, wherein the receiving part includes a receiving part body with a channel for receiving a rod and an accommodation space for the head of a bone anchoring element. The accommodation space has a bottom opening for inserting the head, and a pressure element is at least partially provided in the accommodation space to clamp the head. The pressure element is movable along a longitudinal axis of the receiving part body from an inserting position to insert the head, to a pre-locking position to clamp the head in the receiving part by a pre-stress exerted by the pressure element, and to a locking position to lock the head in the receiving part.

SUMMARY

It is the object of the invention to provide an improved coupling assembly for coupling a rod to a bone anchoring element and a bone anchoring device with such coupling assembly that can be more safely handled during surgery.

The bone anchoring device is a bottom loading type bone anchoring device, wherein the head of the bone anchoring element is inserted into the receiving part from the bottom end. Once the pressure element is mounted to the receiving part, it is prevented from escaping from the top end of the receiving part by a first retaining member. After the head has been inserted into the receiving part and into a flexible cap portion of the pressure element, it is prevented by a second retaining member from being inadvertently pulled out through the bottom end of the receiving part. The first retaining member also holds the pressure element with respect to the receiving part in an aligned position to permit the insertion of a rod. The second retaining member prevents a further upward movement of the pressure element once the head is inserted and holds the pressure member in the pre-locking position. By the second retaining member the step of aligning the coupling assembly with the rod and generally the handling of the bone anchoring device is rendered safer because an inadvertent removal of the head through the lower opening is prevented.

The bone anchoring device is particularly useful for a method of in-situ assembly of the bone anchoring device, wherein first the bone anchoring element is implanted into the bone and then the coupling assembly is mounted to the head.

The coupling assembly can be part of a modular bone anchoring system, wherein a plurality of bone anchoring elements that differ in terms of their shank length, shank diameter, bone anchoring features, such as threads, barbs, etc., shank types, such as solid shanks, cannulated shanks with openings in the shank wall, etc., can be provided with one type of coupling assembly to allow the “on demand” assembly of a specific bone anchoring element with the coupling assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the invention will become apparent from the description of embodiments by means of the accompanying drawings. In the drawings:

FIG. 1 shows a perspective exploded view of a first embodiment of the bone anchoring device.

FIG. 2 shows a perspective view of the bone anchoring device of FIG. 1 in an assembled state.

FIG. 3 shows a perspective view of the bottom of a receiving part according to first embodiment.

FIG. 4 shows a cross-sectional view of the receiving part shown in FIG. 3, the cross-section taken in a plane through the central axis and perpendicular to the rod axis.

FIG. 5 shows a perspective view from the bottom of a pressure element of the first embodiment.

FIG. 6 shows a cross-sectional view of the pressure element shown in FIG. 5, the cross-section taken in a plane through the central axis and perpendicular to the rod axis.

FIG. 7 shows a perspective view of a retaining member of the first embodiment.

FIG. 8 shows a cross-sectional view of the retaining member shown in FIG. 7 along line A-A in FIG. 7.

FIG. 9 shows a cross-sectional view of a step of mounting the pressure element into the receiving part, which includes the second retaining member according to the first embodiment.

FIG. 10 a shows a cross-sectional view of the pressure element mounted to the receiving part after the step shown in FIG. 9.

FIG. 10 b shows an enlarged cross-sectional view of a portion of FIG. 10 a.

FIGS. 11 to 13 show cross-sectional views of steps of inserting the head of the bone anchoring element into the receiving part and the pressure element according to the first embodiment.

FIG. 14 a shows a cross-sectional view of a step of moving the pressure element downward with the head being inserted.

FIG. 14 b shows an enlarged cross-sectional view of a portion of FIG. 14 a.

FIG. 15 a shows a cross-sectional view of the coupling assembly with the pressure element in the pre-locking position and retained by the second retaining member according to the first embodiment.

FIG. 15 b shows an enlarged cross-sectional view of a portion of FIG. 15 a.

FIG. 16 shows a cross-sectional view of the receiving part according to a second embodiment, the cross-section taken in a plane through the central axis and perpendicular to the rod axis.

FIG. 17 shows a perspective view of the pressure element according to a second embodiment.

FIG. 18 shows another perspective view of the pressure element shown in FIG. 17.

FIG. 19 shows a cross-sectional view of the pressure element shown in FIG. 17, the cross-section taken in a plane through the central axis and perpendicular to the rod axis.

FIG. 20 shows a cross-sectional view of a step of inserting the head into the pre-assembled receiving part with pressure element according to the second embodiment.

FIG. 21 shows a cross-sectional view of moving the pressure element downward with the head inserted according to the second embodiment.

FIG. 22 shows a cross-sectional view of the coupling assembly with the pressure element in the pre-locking position and the head inserted according to the second embodiment.

FIG. 23 shows a cross-sectional view of the receiving part according to a third embodiment, the cross-section taken in a plane through the central axis and perpendicular to the rod axis.

FIG. 24 shows a perspective view of the pressure element according to the third embodiment.

FIG. 25 shows a cross-sectional view of the coupling assembly with the head inserted and the pressure element being in the pre-locking position according to the third embodiment.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2, a bone anchoring device according to a first embodiment comprises a bone anchoring element 1 in the form of a bone screw having a threaded shank 2 and a head 3, which is in this embodiment a spherical segment-shaped head. The head 3 has a recess 4 for engagement with a screwing-in tool. The bone anchoring further comprises a coupling assembly 10 including a receiving part 5 for receiving a rod 6 to connect the rod 6 to the bone anchoring element 1 and a pressure element 7 for locking the head 3 in the receiving part 5. The pressure element 7 is held in the receiving part 5, for example, via pins 8 a, 8 b. The rod 6 can be secured in the receiving part via a securing closure element 9, which is in the form of an inner screw.

The receiving part 5 is now explained with reference to FIGS. 1 to 4. The receiving part 5 comprises a top end 5 a and an opposite bottom end 5 b and an axis of symmetry M passing through the top end 5 a and the bottom end 5 b. A bore 51 is provided, which is coaxial with the axis of symmetry M. In a first region adjacent to the top end 5 a, the receiving part 5 comprises a U-shaped recess 52, which is symmetric with respect to the axis of symmetry M, the recess 52 having a bottom directed towards bottom end 5 b and two free lateral legs 53 a, 53 b extending towards the top end 5 a. In the region of the legs 53 a, 53 b, an internal thread 54, which cooperates with the inner screw 9, is provided. A channel formed by the U-shaped recess 52 is sized so as to receive the rod 6 therein to connect a plurality of anchoring devices. The bore 51 is followed by an enlarged accommodation space 55 with a portion having a greater inner diameter than the bore 51 that is intended to accommodate the head 3 and a portion of the pressure element 7 as explained below. The accommodation space 55 comprises a tapered section 56 that tapers towards the bottom end 5 b. The accommodation space 55 opens towards the bottom end 5 b via an opening 57 that has an inner diameter greater than a largest outer diameter of the head 3, so that the head 3 is insertable into the receiving part from the bottom end 5 b. The bore 51 forms a passage that connects the open top end 5 a of the receiving part 5 with the accommodation space.

At a distance from the bottom end 5 b that corresponds approximately to the distance of the bottom of the U-shaped recess 52, an annular groove 58 is provided in the inner wall of the bore 51. The depth of the groove is such that the inner diameter of the receiving part at the groove 58 is greater than the inner diameter of the bore 51. It may be as large as an inner diameter of the accommodation space 55. The groove 58 is configured to receive a retainer ring 11 explained below.

On each leg 53 a, 53 b, bores 59 a, 59 b are provided for receiving the pins 8 a, 8 b. The bores 59 a, 59 b are located approximately at a center of each leg in a circumferential direction and at a position above the groove 58 measured from the bottom end 5 b.

Referring to FIGS. 1 and 5 to 6, the pressure element 7 has a top end 7 a and a bottom end 7 b, a first portion 71, that is substantially cylindrical and that has an outer diameter slightly smaller than the inner diameter of the bore 51, so that the pressure element 7 is movable in the bore 51. It further comprises a second cap-like portion 72 that is recessed with respect to the first portion 71 and that has a maximum outer diameter, which is smaller than an inner diameter of the largest part of the accommodation space 55. The first portion 71 comprises at its end opposite to the second cap-like portion 72 a substantially V-shaped recess 73 for receiving the rod 6 therein, when the pressure element 7 is situated in the receiving part 5. The substantially V-shaped recess 72 permits to insert rods 6 of a different diameter, because for typical rod diameters the contact area of the rod 6 with the pressure element 7 is always along two lines for each rod regardless of its diameter. At the lateral sides of the substantially V-shaped recess, the pressure element comprises two elongate recesses 74 in its outer wall, which are arranged opposite to each other and which are aligned such, that a longer side of the elongate recesses 74 is parallel to the axis of symmetry M of the receiving part 5. The recesses 74 are open towards the top end 7 a and their bottoms 74 a, 74 b provide a stop for the pins 8 a, 8 b when the pins are inserted into the bores 59 a, 59 b and extend slightly into the bore 51. At the end of the first substantially cylindrical portion 71 that faces the cap-like portion 72, there is a circumferentially extending free edge 75 that is generated by a circumferentially extending groove 75 a arranged at a height approximately of the bottom 74 a, 74 b of the recesses 74. The free edge 75 comprises a slanted lower surface 75 b that is slanted towards the axis of symmetry M and towards the bottom end 7 b. The slanted surface portion 75 b is configured to cooperate with the retainer ring 11.

The second, cap-like portion 72 comprises a first end at the side of the first portion 71, which is recessed with respect to the first portion 71 and a second end that is the second end 7 b of the pressure element. Through the cap-like shape, a hollow interior 76 is provided that is substantially spherically-shaped to clamp a spherical head 3 therein. At the second end 7 b, an opening 77 for inserting the head 3 is formed. An outer wall of the second portion 72 comprises a spherical first portion 72 a and a second tapered portion 72 b adjacent to the opening 77. The tapered second portion 72 b of the pressure element 7 cooperates with the tapered portion 56 of the receiving part. The second portion 72 of the pressure element further comprises a plurality of slits 78 extending from an edge of the opening 77 through the second portion 72. The number and dimensions of the slits 78 are such that the wall of the second portion is flexible enough to snap onto the head 3, when the head 3 is being inserted. The closed end 78 a of the slits 78 may be widened with a circular contour to increase the flexibility of the cap-like second portion 72. The inner diameter of the cap-like portion as a whole or only in a section adjacent to the bottom end 7 a may be such that it has a slight undersize with respect to the size of the head 3 so that the head 3 can be clamped by the cap-like portion 72 by friction. The pressure element 7 further comprises a coaxial bore 79 for providing access to the screw head 3 by a tool.

The pressure element 7 is a monolithic piece. This contributes to a simple design as only one part is required to clamp the head and take up the rod. Furthermore, the first portion 71 of the pressure element 7 is designed as a solid, non-resilient portion that is configured to cooperate with a resilient part, such as the retainer ring 11 to provide a counter-force that deforms the corresponding resilient portion as explained below.

The retainer ring 11 has a top end 11 a and an opposite bottom end 11 b and a slit 111 extending from the top end 11 a to the bottom end 11 b through the retainer ring 11. The slit 111 renders the retainer ring 11 flexible in a radial direction such that the outer diameter of the retainer ring 11 decreases when the retainer ring 11 is compressed in radial direction and the slit 111 narrows and the outer diameter increases when the ring is expanded and the slit becomes larger. An outer diameter of the retainer ring 11 in a non-compressed state is such that as shown in FIGS. 9 to 10 b, the retainer ring 11 is held in the groove 58 of the receiving part 5 with a space between the outside of the retainer ring and the bottom of the groove, as can be seen in particular in FIG. 10 b. The retainer ring 11 further has a slanted inner surface portion 112 that has substantially the same angle with respect to the central axis M as the slanted surface portion 75 b of the annular free edge 75 of the pressure element 7. The slanted surface portion 112 of the retainer ring 11 is configured to cooperate with the slanted surface portion 75 b of the annular free edge 75 of the pressure element 7. An outer surface of the retainer ring 11 is substantially cylindrical. Because a cross-section of the groove 75 a that is configured to accommodate at least a portion of a retainer ring 11 is substantially rectangular, the retainer ring 11 has a corresponding substantially rectangular contour of the outer surface portion that fits into the groove. However, other matching shapes of the cross-section of the groove and the outer contour of the retainer ring may be contemplated.

All parts described before may be made of a bio-compatible material, such as a bio-compatible metal like stainless steel or titanium, or a bio-compatible metal alloy, for example Nitinol, or are made from a bio-compatible plastic material, for example polyetheretherketone (PEEK). The parts may be all of the same or of different materials.

The steps of pre-assembling the coupling assembly are explained with reference to FIGS. 9 to 10 b. First, the retainer ring 11 is inserted into the groove 58 provided at the inner wall of the receiving part 5. Because the retainer ring 11 is resilient due to its slit 111, it can be compressed in radial direction and inserted into the receiving part 5, for example, through the top end 5 a. Once the retainer ring 11 has reached the groove 58, it can expand so that, as shown in the Figures, it partially extends into the groove 58. Thereafter, as indicated by the arrow F in FIG. 9, the pressure element 7 is inserted through the top end 5 a into the receiving part until its cap-like portion 72 extends into the accommodation space 55. Because the cap-like portion 72 is flexible, it can be compressed in order to be guided through the coaxial bore 51. The pressure element 7 is moved downward until the slanted surface portion 75 b of the free edge 75 of the first portion 71 abuts against the slanted surface portion 112 of the retainer ring 11. In this configuration, shown in FIGS. 10 a and 10 b, the pins 8 a, 8 b are inserted into the bores 59 a, 59 b until they extend into the elongate recesses 74 of the pressure element 7, as shown in FIG. 10 a. In this configuration, the pins 8 a, 8 b provide an abutment for the pressure element 7 that limits an upward movement of the pressure element 7 in the insertion position. Hence, the pins 8 a, 8 b form a first retaining element that retains the pressure element 7 in the receiving part 5. Simultaneously, in this position, the retainer ring 11 provides an abutment for a further downward movement of the pressure element 7 so that the cap-like portion 72 of the pressure element is held in the accommodation space 55, 56 without having contact to the inner wall of the accommodation space.

In use, the bone anchoring device is assembled by inserting the head 3 into the receiving part 5 with the inserted pressure element 7. In one embodiment, the bone anchoring device is assembled outside a patient's body such that a suitable bone anchoring element is selected prior to surgery according to specific details of the particular clinical application and then inserted into the coupling assembly. In another embodiment, a bone anchoring element is inserted into a bone or a vertebra prior to assembling it with the coupling assembly. The coupling assembly is then mounted in-situ to the implanted bone anchoring element.

Steps of mounting the coupling assembly to the bone anchoring element are described with reference to FIGS. 11 to 15 b. First, as shown in FIG. 11, when the pressure element 7 is inserted into the receiving part 5 and held by the pins 8 a, 8 b, it is shifted into its uppermost position, which is an insertion position for allowing the head 3 of the bone anchoring element to be inserted. The insertion position is limited against an upward movement by the abutment provided by the engagement of the pins 8 a, 8 b with the bottom 74 a, 74 b of the elongate recesses 74. In the insertion position, the flexible cap-like portion 72 of the pressure element 7 is positioned freely in the accommodation space 55. The head is then inserted through the lower opening 57 of the receiving part 5. Due to the flexibility of the wall provided by the slits 78, the cap-like portion 72 expands in the accommodation space 55 as shown in FIG. 12. The cap-like portion 72 snaps onto the head 3 until it encompasses the head 3 as shown in FIG. 13. The pins 8 a, 8 b, also prevent the pressure element 7 from escaping through the open top end 5 a when the head 3 is inserted and tends to move the pressure element 7 upwards during insertion. In the insertion position, the head 3 is pivotable in the receiving part 5 and also removable. During the insertion of the head 3, the receiving part 5 may be held by an instrument (not shown).

FIGS. 14 a and 14 b show the movement of the pressure element 7 into the pre-locking position of the pressure element 7. When the head 3 is inserted and the pressure element 7 is pressed down slightly, for example by an instrument, the slanted surface portion 75 b of the free edge 75 of the first portion 71 of the pressure element 7 is guided by the slanted surface portion 112 of the retainer ring 11, thereby expanding the retainer ring 11 in a radial direction so that the retainer ring 11 is further pressed into the groove 58. Simultaneously, the tapered exterior surface portion 72 b of the cap-like portion 72 of the pressure element 7 contacts the tapered portion 56 of the accommodation space 55 of the receiving part 5.

A further downward movement of the pressure element 7 into a pre-locking position results in the free edge 75 passing the retainer ring 11 until an upper side 75 c of the free edge 75 engages the bottom end 11 b of the retainer ring. Because there is the groove 75 a in the first portion 71 of the pressure element 7, the retainer ring has space to contract and moves into the groove 75 a. Hence, the bottom end 11 b of the retainer ring provides an abutment for the free edge 75 of the pressure element that prevents the pressure element from moving upward again. Also, the opening 57 is narrowed by the presence of the tapered portion 72 b of the cap-like portion 72 of the pressure element 7, thereby preventing the head 3 from removal through the lower opening 57 in the pre-locking position. If the cap-like portion 72 has at a section adjacent to the bottom end 7 b a slight undersize with respect to the head, the friction hold of the head can be optimized. This allows to repeatedly achieve a certain friction force.

In further use, at least two bone anchoring devices are connected through a rod 6. Because of the friction hold of the head 3, the alignment of the receiving parts for taking-up the rod is facilitated. Finally, the closure element 8 is inserted and tightened, which further presses down the pressure element so that by the engagement of the lower part of the cap-like portion 72 with the receiving part 5 the head 3 is locked in a specific angular position.

A coupling assembly according to a second embodiment is shown in FIGS. 16 to 18. It differs in the design of the receiving part and the pressure element. The receiving part 5′ does not have the groove 58 but instead comprises a retaining element in the form of a projection provided at an inner wall of the receiving part 5′. All parts and portions that are identical or similar to that of the first embodiment, are indicated with the same reference numerals and the description thereof will not be repeated. The receiving part 5′, as shown in FIG. 16, comprises at a position below the internal thread 54, a projection 60 that extends in a circumferential direction at the inside of the legs 53 a, 53 b. The projection 60 is separated from the internal thread 54 by a first undercut or recessed portion 61 below the internal thread 54 and is further separated from the coaxial bore 12 by a second undercut or recessed portion 62. An inner diameter of the coaxial bore 12 in the region of the projection 60 is not changed, so that the projection 60 is easy to manufacture. The depth of the undercut 61 corresponds approximately to the root of the internal thread, whereas the depth of the undercut 62 may be smaller, as the undercut 62 serves only as a space for a portion of the pressure element as explained below.

The pressure element 7′ of the second embodiment differs from the pressure element 7 according to the first embodiment in the design of the first portion while the design of the second portion is similar or identical to the first embodiment. The first portion 71′ of the pressure element 7′ comprises on each side of the substantially V-shaped recess 73′ two upstanding resilient arms 80 a, 81 a that are separated from a central portion comprising the V-shaped recess 73′ by a gap 82 a, 82 b in order to provide flexibility of the arms 80 a, 81 a, 80 b, 81 b. The flexible arms 80 a, 81 a and 80 b, 81 b extend above the central portion and on each side, the arms are separated by an elongate recess 74′, the bottom 74 a′, 74 b′ of which provides an abutment for the pins 8 a, 8 b. The outer surface portion of the flexible arms may be cylindrical. Each arm 80 a, 81 a, 80 b, 81 b has at its free end an outwardly projecting collar portion 83 a, 84 a, 83 b, 84 b, which has a substantially circle segment-shaped outer contour in order to fit into the bore 51 when the pressure element 7′ is inserted into the receiving part 5′. As can be seen in particular in FIGS. 18 and 19, a lower surface portion 831 a, 841 a, 831 b, 841 b of the collar portions 83 a, 84 a, 83 b, 84 b is slanted so as to permit a smooth movement of the pressure element 7′, when it is inserted into the receiving part 5′. The arms 80 a, 81 a, 80 b, 81 b are flexible in such a way that they can be deflected towards the central axis and can resiliently move back to their upright position. The dimensions of the flexible arms are such that when the pressure element 7′ has been inserted into the receiving part 5′ and the pins 8 a, 8 b engage the bottom 74 a′, 74 b′ of the elongate recesses 74′, the collar portions 83 a, 84 a, 83 b, 84 b extend into the first undercut 61.

In the pre-assembled state, the pressure element 7′ has been inserted into the receiving part 5′ and the pins 8 a, 8 b are inserted and engage the elongate recesses 74′ so that the pressure element 7′ can not inadvertently move out through the top end 5 a.

Referring now to FIGS. 20 to 22, the insertion and pre-locking of the bone anchoring element is explained. First, as depicted in FIG. 20, the pressure element 7′ is in the insertion position and the head 3 has been already inserted into the receiving part 5′ and into the cap-like portion 72 of the pressure element 7′. During insertion of the head 3, the pressure element 7′ is moved upward until the bottom 74 a′, 74 b′ of the elongate recesses 74′ abuts against the pins 8 a, 8 b. Hence, the pins 8 a, 8 b provide a first retaining element to retain the pressure element 7′ in the insertion position. Thereafter, the pressure element is moved downward, for example by an instrument, whereby the flexible arms 80 a, 81 a, 80 b, 81 b slide with their slanted surfaces 831 a, 841 a, 831 b, 841 b of their collar portions 83 a, 84 a, 83 b, 84 b along the projection 60. By means of this, the projection 60 compresses the flexible arms towards each other as shown by the transverse arrows f in FIG. 21. Further downward movement of the pressure element 7′ moves the collar portions 83 a, 84 a, 83 b, 84 b under the projection 60 in the receiving part 5′, so that the collar portions can expand into the second undercut 62 of the receiving part 5′. Simultaneously, the tapered outer surface portion 72 b of the cap-like portion 72 of the pressure element 7′ engages the tapered section 56 of the accommodation space of the receiving part 5′. This pre-locking position of the receiving part 7′ is maintained by the abutment, which is provided by the projection 60, that prevents an upward movement of the pressure element 7′. Hence, the projection 60 acts as a second retaining element. The head 3 can not be removed, because the lower opening 57 of the receiving part 5′ is narrowed by the cap-like portion 72 of the pressure element 7′.

A third embodiment of the coupling assembly is described with reference to FIGS. 23 to 25. The coupling assembly differs from the first and second embodiment in the design of the receiving part and the pressure element. Parts and portions of the receiving part and the pressure element that are identical or similar to the first and second embodiment, are indicated with the same reference numerals and the description thereof is not repeated. The receiving part 5″ comprises instead of a continuous cylindrical bore 51 an internal hollow conically-shaped portion 120 that widens towards the top end 5 a as shown in FIG. 23. The hollow conically shaped portion 120 extends between a position corresponding to approximately the bottom of the U-shaped recess 52 until a position below the internal thread 54 of the receiving part 5″. By means of this, an undercut portion 120 a below the end of the internal thread 54 is provided. Simultaneously, the crest of the last turn of the internal thread 54 provides a projection 60″ that serves as an abutment for the flexible arms of the pressure element 7″.

The pressure element 7″ comprises in the first main portion 71″ on each side of the V-shaped recess 73″ two upstanding flexible arms 80 a″, 81 a″, 80 b″, 81 b″. The flexible arms 80 a″, 80 b″, 81 b″ extend conically outward from the main portion 71″ with a size and cone angle corresponding to the conical section 120 of the receiving part 5″. The flexible arms 80 a″, 81 a″, 80 b″, 81 b″ have a conical outer surface portion and conical inner surface portion and are thin enough so that they can be flexed inward, when a compression force acts on them. As in the second embodiment, the flexible arms are separated from the central portion 71″ that comprises the V-shaped recess 73″ by a gap 82 a″, 82 b″.

In use, when the pressure element 7″ is inserted from the top end 5 a into the receiving part 5″, the flexible arms are compressed and flexed inward. In the insertion position (not shown in the Figures), the flexible arms are compressed and extend into the region with the internal thread 54, while the pins 8 a, 8 b secure the pressure element 7″ from moving upward. To obtain the pre-locking position, the pressure element 7″ is moved further downward until the flexible arms snap into the undercut portion 120 a below the projection 60″ provided by the internal thread 54. In this pre-locking position, the cap-like portion engages the lower portion of the accommodation space and a removal of the head 3 through a lower opening is prevented.

Further modifications of the embodiments shown may be contemplated. For example, the head of the bone anchoring element can have any other shape, such as a cylindrical shape, whereby a monoaxial bone screw is provided allowing rotation of the screw element with respect to the receiving part around a single axis. Also an uni-planar configuration may be contemplated, wherein the cap-like portion of the pressure element and the head are defined so as to allow a pivoting in only a single plane.

The pressure element according to the second and third embodiment may have one flexible arm on each side or more than one flexible arm on each side. For example, the pressure element according to the second embodiment may have recesses 74′ that are closed towards the top end 7 a. This results in one flexible arm on each side with an increased top surface area of the arms.

While pins are shown for realizing the first retaining element, the first retaining element can be realized otherwise, for example, through crimping. Also other modifications, such as flexible elements to retain the pressure element in the insertion position, may be contemplated.

For the bone anchoring element, any bone anchoring element can be used such as bone anchors with threads, which barbs, cannulated bone anchors or two-part bone anchors, where the head and the shank are separate parts.

For holding the head in a pre-locking position, the shape of the lowermost section of the accommodation space near the opening and the shape of the lowermost section of the pressure element can be designed otherwise than tapered, for example rounded or straight. 

1. A coupling assembly for coupling a rod to a bone anchoring element, the coupling assembly including a receiving part with a top end and an opposite bottom end; a section for receiving the rod and an accommodation space for accommodating a head of the bone anchoring element, the accommodation space being in communication with the top end of the receiving part through a passage and being in communication with the bottom end through an opening at the bottom end for inserting the head; and a pressure element located at least partially in the accommodation space, the pressure element having a cap portion configured to encompass the head; wherein the pressure element can assume in the receiving part an inserting position in which inserting of the head into the receiving part is permitted, a locking position in which the head can be locked in the receiving part and a pre-locking position in which the pressure element is pivotable in the receiving part and wherein the pressure element is arranged such that the cap portion narrows the opening at the bottom end to prevent removal of the head. wherein a first retaining element is provided that prevents the pressure element from moving further towards the top end in the insertion position and wherein a second retaining element different from the first retaining element is provided that prevents the pressure element from moving further towards the top end in the pre-locking position.
 2. The coupling assembly of claim 1, wherein the second retaining element is a member that is separate from the receiving part and the pressure element and that is configured to narrow the passage.
 3. The coupling assembly of claim 1, wherein the second retaining element is a slit ring that is resilient in a radial direction and that is accommodated at least partially in a groove provided in the first passage.
 4. The coupling assembly of claim 1, wherein the pressure element comprises a first portion that interacts with the second retaining element and that is a solid portion without spring portions.
 5. The coupling assembly of claim 3, wherein the slit ring has a first slanted surface portion that is slanted with respect to a central axis of the receiving part and wherein the pressure element has a second slanted surface portion cooperating with the first slanted surface portion so as to expand the slit ring when the pressure element is moved from the insertion position into the pre-locking position.
 6. The coupling assembly of claim 1, wherein the second retaining element is a projection provided in the first passage and which is followed towards the bottom end by an undercut portion that allows expansion of the pressure element.
 7. The coupling assembly of claim 6, wherein the pressure element comprises flexible arms that are compressed towards each other when the pressure element is inserted and passes by the second retaining element.
 8. The coupling assembly of claim 6, wherein the passage comprises a conical portion that widens towards the top end.
 9. The coupling assembly of claim 8, wherein the pressure element comprises flexible arms that conically extend outwards.
 10. The coupling assembly of claim 1, wherein the second retaining element is configured to allow a downward movement of the pressure element from the insertion position into the pre-locking position only once.
 11. The coupling assembly of claim 1, wherein the first retaining element is at least one, preferably two pins that project into the passage and engage corresponding recesses in the pressure element.
 12. The coupling assembly of claim 1, wherein the accommodation space is substantially cylindrical with a narrowing portion near the opening, the narrowing portion being preferably tapered or rounded.
 13. The coupling assembly of claim 1, wherein the cap-like portion of the pressure element is sized so as to exert a pre-stress onto the head that holds the head by friction.
 14. The coupling assembly of claim 1, wherein the pressure element is a monolithic piece.
 15. A bone anchoring device comprising the coupling assembly according to claim 1 and a bone anchoring element having a shaft and a head and wherein preferably a closure element is provided for securing the rod in the receiving part. 